Anodic bonding

ABSTRACT

1,138,401. Joining glass and metal. P. R. MALLORY &amp; CO., Inc. 22 April, 1966 [6 May, 1965; 6 Dec., 1965], No. 17792/66. Heading C1M. [Also in Divisions B3, C7 and H1] An electrically conductive or semi-conductive material is joined to an insulating material (glass, quartz, sapphire) by forming an electrolytic interface layer of oxide, the joining being conducted at a temperature sufficiently high to render the non-conductive material electrically conducting but not sufficiently high to melt either component. The components are solid state electronic devices (see Division H1). Particular conductive or semi-conductive materials referred to are: silicon, aluminium, germanium, gallium arsenide, platinum, beryllium, titanium and palladium.

Aug.- 13, 1968 D. l. POMERANTZ ANODIC BONDING 4 Sheets-Sheet 1 Filed Oct. 5, 1966 Z T M .0, R 0% mm E0 VP N. l I n a 2 I. Y B N 2 D- 6 3 H ATTORNEY 3,1968 D. POMERANTZ 3,397,278'

ANODIC BONDING 5 INVENTOR DANIEL I. POMERANTZ ATTORNEY g- 1968 D. POMERANTZ 3,397,278

ANODI G BONDING 7 Filed Oct. 5-, 1966 v 4 Sheets-Sheet 5 37 35 4O 33 3e 32 37 71 1 i1 "v INVENTOR DAN/EL 1'. POMERANTZ BY fly v ATTOR N Y United States Patent 3,397,278 ANODIC BONDING Daniel I. Pomerantz, Lexington, Mass., assignor to P. R. Mallory & Co., Inc., Indianapolis, Ind., a corporation of Delaware I Continuation-impart of application Ser. No. 453,600, May 6, 1965. This application Oct. 3, 1966, Ser. No. 583,907

23 Claims. (Cl. 174-52) ABSTRACT OF THE DISCLOSURE An inorganic insulator element of normally high electrical resistivity is bonded to a metallic element by placing the substantially smooth and complemental adjoining surfaces of the elements in contact, heating the insulator element to increase its electrical conductivity and applying a potential across the elements thereby producing an electric current through the elements and creating an electrostatic field whereby the elements are brought into intimate contact with each other and a bond is formed. The foregoing is useful, for example, to encapsulate a planar surface of a silicon semiconductor device with a glass.

The present invention relates to semiconductor devices and more particularly relates to a novel method of bonding metals including semiconductors to insulators and the product thereof. This application is a continuation-in-part of my copending application, application Ser. No. 511,771 filed Dec. 6, 1965 which in turn is a continuation-in-part of my copending application Ser. No. 453,600, filed May 6, 1965. Both of these applications are now abandoned.

One aspect of bonding metals to insulators involves semiconductor devices having diffused p-n junctions. In such semiconductor devices it is well known that the exposed boundaries are extremely sensitive to environmental conditions, and it has become general practice to provide protection in the form of controlled ambients or coatings. In order to provide this protection for semiconductor p-n junction devices, commercial development has led to the provision of costly and complex housings or enclosures which protect the p-n junction but prevent full realization of the full advantage of semiconductor devices. It is known in the art to use the semiconductor material as an integral part of the encapsulation. However, this structure leads to complexities in regard to the attachment of external leads and the use of metal part members which increase the cost and fabrication effort for such devices. It is also known in the art to enclose the planar surfaces of silicon semiconductor devices by sandwiching a ring of hard glass bet-ween the silicon wafer containing the diffused junctions and a plain silicon wafer to be used as a cap, metallizing the surfaces to be bonded, and creating a bond by exposing the assembly to temperature suflicient to cause a heat bond. A glass-to-semiconductor seal is thereby provided by causing sufiicient melting of the materials so that bonding occurs. However, as the surfaces to be bonded must be first plated with a metal, usually gold, the resulting bond is actually a glass-to-metal seal. While this method eliminates the step of soldering the metallized surfaces, it is still cumbersome and requires a number of complicated steps.

Therefore, it is an object of the present invention to ice provide an improved method of encapsulating the plana1 surfaces of silicon semiconductor devices and monolithk circuits having diffused p-n junctions which overcome: the disadvantages of prior art.

It is an object of the present invention to reduce tl'lt number of parts used in semi-conductor p-n junction de vices and monolithic circuits.

It is an object of the present invention to reduce th number of steps and hence the time in the fabricatior of semiconductor p-n junction devices and monolithit circuits.

In its more general aspects the present invention con cerns the bonding of an electrically conductive elemen to an insulator element. As will be seen from the variou: specific examples described herein the electrically con ductive element may be a metal of high conductivity sucl as aluminum or a metal of lower conductivity such a: silicon commonly referred to as a semiconductor. Th1 insulator element is of the type or character compriset of inorganic material having normally at room tempera ture a relatively high electrical resistivity but capable 0 being rendered moderately conductive at elevated tern peratures. The various glasses are illustrative of the in sulators contemplated.

In accordance with the foregoing it is an object of the present invention to provide a method of bonding a1 insulating material directly to a conductive material, semiconductor material, a semiconductor device or a monolithic circuit, thus eliminating the steps of meta plating the surfaces to be bonded and the soldering 0 heat fusing of the metallized surfaces to effect connec tions therebetween.

The present invention, in another of its aspects, relate to novel features of the instrumentalities described here in for attaining the principal object of the invention an to the novel principles employed in the instrumentalitie whether or not these features and principles may be use in the said object and/or in the bonding field.

Other objects of the invention and the nature thereo will become apparent from the following description con sidered in conjunction with the accompanying drawing and wherein like reference numbers describe elements 0 similar function therein.

For illustrative purposes, the invention will be de scribed in conjunction with the accompanying drawing in which:

FIGURE 1 is a cross-sectional view of the simpl method of bonding a semiconductor to an insulator;

FIGURE 1a is a fragmentary cross-sectional view, 01 an enlarged scale, of a typical relation at the interfac of a semiconductor and an insulator such as shown i1 FIGURE 1 in the process of being bonded;

FIGURE 2 is a cross-sectional view of a planar diod encapsulated by anodic bonding;

FIGURE 3 is a pictorial view of a transistor chip am the metallized insulating block prior to alignment anl anodic bonding;

FIGURE 4 is a cross-sectional view of a silicon transis tor chip and a metallized insulator prior to anodic bond ing taken through section 44 of FIGURE 3;

FIGURE 5 is a cross-sectional view of the complete encapsulated transistor;

FIGURE 6 is a cross-sectional view of a planar diod and a transistor encapsulated and interconnected bj anodic bonding;

FIGURE 7 is a cross-sectional view of the planar diode and transistor of FIGURE 6 illustrating an initial step in 'orming the article of FIGURE 6 according to one techlique; and

FIGURE 8 is a view similar to FIGURE 7 illustrating LI). initial step in forming the article of FIGURE 6 cm- )loying a somewhat different technique.

FIGURES 1 and 1a illustrate the general principles of he invention. In accordance therewith an insulator such LS a borosilicate glass and a semiconductor such as silicon [1'6 brought into close surface contact, the juxtaposed urfaces being smooth and flat, the insulator is heated ufficiently to render it electrically conductive. When the nsulator is borosilicate glass such as obtainable from the Dorning Glass Works under the trademark Pyrex, a emperature range of about 300 C. to 700 C. may be mployed to render the glass suitably conductive. A bond then effected by applying an electric power source .cross the assembled unit producing a small current flow. current of low amperage is sufficient. It will be noted lso that the temperatures employed are below the softenng points of the glass and similarly below the melting roints of the metals. In a typical example with a semi- :onductor of silicon and an insulatng material of boroilicate glass the bond is effected by a current of 10 micromperes/mm. for a period of about one minute. The 'rocess is clearly distinguishable from electrical welding s the joule heat developed is not sufficient to create any usion in gross of materials. In the present invention subtantial fusion by application of heat is avoided. Thus it llll be understood that the magnitude of electrical curent employed in the practice of this invention may be venominated as current of low density.

It will be understood that the temperatures employed re those which are required to be met in order to render he insulator material sufficiently electrically conductive a permit the passage of a finite current. It is this small lectric current which produces the bonding phenomena 1 a bonding or transition zone at the interface between he insulator and the semiconductor or conductor.

Although the values 10 microamperes/mm. for one iinute are used above in describing the present invention, be current and time may be varied infinitely, so long as he current-time product is sufficient for bonding growth. he values of current density and time will vary dependnt upon the materials being bonded and the temperature mployed. For example, in a particular case a fractional iicroampere passed through the system for a relatively Jng period of time will produce the bonding film, as will milliampere passed for 0.6 second. The times will vary ccording to the current. Similarly where to produce a 0nd with a current of 1 microampere would require pasage of the current for approximately 10 minutes, if a curent of 20 microamperes is passed through the system, nly about 30 seconds are required to form a bond.

A specific example of the bonding of silicon to boroilicate glass is given above. As an example of bonding llicon to quartz glass a current of approximately 10 iicroamperes/mm. for one minute is employed the temerature being in the range of between about 700 C. and 200 C. As noted above where the insulator is Pyrex lass the temperature range may be from 300 C. to 00 C., although temperatures as low as 150 C. and s high as about 800 C. may be used in some instances. he temperature for soft glass while in approximately the ame range generally will be somewhat lower to avoid .lSlOl'l, and for glass of the ceramic type such as porcelain 1e ranges applicable to Pyrex are suitable. In any event 1e temperature employed should be below the fusion temerature of the glass. As heretofore pointed out the reuirement is that the temperature be such as to render to normally high resistance material slightly conductive .ectrically and capable of passing a low current. Norlally even with the insulator at an elevated temperature considerable voltage is required in the range of several "the desired amperage, depending, of course, upon such factors as the character of the insulator and its thickness.

The present invention may advantageously be employed in packaging electronic components. In some forms of hybrid integrated circuits, it is desirable to attach a number of discrete semiconductor chips to an insulating substrate and subsequently interconnect them or to interconnect and encapsulate a plurality of silicon monolithic circuits on a single substrate. The present invention provides a simple means for accomplishing both steps. The method may further be used for encapsulating silicon semiconductor devices, especially of the planar variety, by bonding an insulating plate to the planar surface of the device. Although semiconductor-insulator bonds are stressed in the illustrative description of the present invention, bonding of more highly conductive metals to insulators is attained by the same method and have particular application to the glass-to-metal seal area.

Referring now to FIGURES l and la which show the invention in its simplest aspect, semiconductor chip 10 is placed on a resistance heated strip 11. Insulator plate 12 is placed on semiconductor chip 10 and a light pressure contact 13 is placed on insulator 12. Pressure contact 13 is connected to a negative pole of a DC. power supply 15, and resistance heated strip 11 is connected to a positive pole 16 of the DC. power supply 15. In obtaining a bond between the semiconductor and insulator, the system is heated until the insulator is slightly conductive. A small positive current is then passed from the semiconductor to the insulator thereby forming anodically grown bond 17. Neither material undergoes melting either by the heat or the current. The heating renders the insluator conductive. The bonding is effected solely by the step of passing a positive electric current from the conductor or semiconductor to the insulator. In the specific example the heating is affected through a resistance plate 11 connected to a suitable electric power source 18. However, other common heating means such as a gas or electric oven may be employed for the purpose. Normally the heat will be maintained while the bonding from current source 15 is being effected particularly if the conditions employed comprise a low current and a substantial period of time. In the diagrammatic showing of FIGURE 1 the bonding circuit is indicated as a power source supplying a steady direct current, which as commonly referred to, is in the direction from the semiconductor 10 to the insulator 12, that is the semiconductor is connected to the positive pole and comprises the anode and the insulator is negative or the cathode. With certain insulators such as the borosilicate glass referred to in the example this orientation of the electrical poles and direction of current has been found to be the most effective. It may be considered that this effectiveness results, at least in part, from the polarization of the borosilicate glass by reason of the current flow at the points of contact. Instead of a steady direct current a pulsating current may be employed.

Also, an AC. source may be employed under certain limited conditions including particularly a low frequency below about 50 cycles per second. Bonding with the use of AC. is more readily achieved with an unoxidized semiconductor as distinguished from one bearing an oxidized surface derived in the formation of the semiconductor element. Since the bonding phenomena are not reversed by or impeded by the use of alternating current and the bonding proceeds with the use of such current of reversing polarity, it appears that the bonding is not degraded or destroyed by such reversal of polarity and perhaps the bonding may indeed be extended and continued during the reverse polarity phase of the alternating current.

It will be understood that when the expression is used herein of passing a positive electric current from a first component to another component, it is meant that said first component is the anode or positive side, and that the current is flowing in the direction opposite to the direction of electron flow as conventionally described, and furthermore that the current may be continuous or intermittent.

Although the exact phenomenon which takes place, and the precise character of what has been referred to as the bonding film, have not been determined, certain physical manifestations have been observed which can be pointed out. In the bonding of borosilicate glass and silicon it has been noted in looking down upon the insulator as bonding proceeds, that certain changes in appearance occur progressing laterally in the bonding region indicating that the bonding occurs progressively at the interface from the initial points of contact. As will be readily understood, even with materials having very smooth surfaces, when they are brought together there is initially intimate contact at only spaced points. FIG- URE la is an enlarged scale cross section of an interface between elements such as are indicated in FIGURE 1 and illustrating a typical case in which there is initially a point contact at the area indicated at P, with a gap G between the opposed areas A and B of the semiconductor and the insulator 12 respectively. The gap may be of varying thickness and while extremely thin is nevertheless appreciable. In FIGURE 1a the relation is, of course, considerably magnified for clarity.

Normally there will be a plurality of such points P and air gaps G. The extent if any to which local plasticity of the materials cooperate has not been determined. At any rate, when electric potential is applied across the lamination, bonding is effected and progresses with formation of a bonding interface. It appears with reference to FIGURE la that polarization occurs and an electrostatic attractive force is set up between areas A and B at P and closely adjacent thereto which tends to draw the members together at those areas and a bond is effected. This phenomenon progresses on to other areas as evidenced by the progressive disappearance of interference fringes and bonding occurs at all areas as they come into close intimate contact so that a close hermetic seal is obtained throughout the interface. Of course, it is still important that the common surfaces be in at least close promixity at all areas. Thus with planar surfaces they should be smooth and complemental over the areas desired to be bonded.

Reference has been made to anodic bonding and to a bonding film and to the bond, and in FIGURE 1 there is shown a layer 17 as a distinct zone contrasting in appearance with the material of the semiconductor 10 and the insulator 12. It is believed an oxide is formed at the interface as a distinct reaction product resulting from the electric current but because the bonding area or zone is of such minute thickness it is impossible or at least most difficult to determine with any degree of certainty the exact physical or chemical change occurring in that region or zone. Measurements made indicate that the bonding region or zone may extend to a depth in the order of 20 to 200 Angstroms. Any attempted analysis is complicated further by the fact that an oxide quickly forms on silicon when exposed to oxygen present in the atmosphere or liberated near the surface of the silicon.

At any rate, bonding accomplished according to the process of this invention produces at the interface between the insulator and semiconductor or conductor a bonding region or layer comprising a composition which is different from that of the semiconductor or conductor and the insulator and which is of higher resistivity than the insulator beyond the bonding region. This has schematically been shown in FIGURE 1 as a layer 17, but it may not be assumed that the bonding region is a homogeneous layer or a layer of constant composition, rather it is a bonding or transition region created by the passage of current under temperature conditions whereby the insulator is rendered conductive and electrostatic attraction occurs in the vicinity of the point of contact. Accordingly when reference is made herein to a film or bonding film at the interface there is meant a region or layer at the interface which is formed or modified in some manner by the passing of the electric bonding current such as to cause the insulator and the semiconductor or conductor to be hermeticaly sealed together by a strong bond throughout. Likewise by anodic bonding there is meant the bonding which results when an electric potential is applied across the juxtaposed elements and electric current flows under the conditions described resulting in a bonding medium of some kind at the interface of the juxtaposed elements which is the result of the electric current flow.

Preferably the semiconductor or metal and the insulator should have a similar thermal coefficient to reduce the liability of separation on cooling or temperature cycling of the unit. Silicon and certain glasses including particularly Pyrex comprise an ideal combination in this respect having coefficients which are close in value. In general separation is less liable to occur in the case of a ductile metal. Also, in any case slow cooling helps to avoid separation.

In a specific example employing borosilicate glass (Pyrex No. 7740) and silicon the bonding current was 10 microamperes/mm. for a period of 20 minutes and the temperature was about 400 C.

In a typical example where quartz glass is used as the insulator and the semiconductor is silicon the system was heated to approximately 900 C. and the electric current was approximately 10 microamperes/mm. for approximately one minute. As another example with these materials a current of 4 microamperes/mm. for approximately 20 minutes at about 900 C. produces bonding.

The general application of the principles of the invention is illustrated by further examples selected from many which have been performed in each of which a firm strong hermeticaly sealed bond resulted.

A germanium semiconductor was bonded to borosilicate glass by a method generally illustrated by FIGURE 1, the conditions being approximately a bonding current of 3 microamperes/mm. for 2 minutes at 450 C.

As examples of other insulator materials a silicon semiconductor was bonded to a soft glass insulator using 5 microamperes/mm. for 4 minutes at 450 C. Also a silicon semiconductor was bonded to a sapphire insulator using 1 =microampere for 1 minute at 650 C.

In another example a semiconductof of gallium arsenide was bonded to soft glass using 25 microamperes for 3 minutes at 450 C.

In FIGURE 2 a planar diode 20 encapsulated by the present invention is shown. The fabrication of this device represents almost the utmost in simplicity, A suitable semiconductor such as a single crystal silicon material is prepared in slice form by techniques which are well known in the art. Slice 21 from which planar diode 20 is to be fabricated is subjected to diffusion heat treatment using a significant impurity to produce p-n junction 23 at a prescribed distance from one surface. Specifically, the lower or major portion 21a of slice 21, which serves as a cathode, is of n-type conductivity silicon. A p-type impurity such as boron is diffused into one face of the slice to convert a surface portion 21b to a p-type conductivity. P-type conductivity portion 21b serves as the anode. An insulating plate 24 is placed on the oxidized surface 26 of silicon slice 21. The insulating plate 24 is preheated by suitable means such as indicated in FIGURE 1.

While in FIGURE 2 the glass 24 is shown as extending to approximately the projection of the p-n junction it is generally preferred to extend the glass portion somewhat beyond the p-n junction to provide maximum protection of .the junction as is clearly shown for example in FIGURE 7.

An electric potential is applied to the components which may be of a character similar to that of FIGURE l and as the current passes through the unit a bonding 51m or zone is formed indicated at 26. It will be understood that the so-called films 26 and 26' are greatly :xaggerated in thickness and in being indicated as distinct separate layers whereas these areas in the final product ire physically indistinguishable from each other by any :ommon or simple analytical techniques.

An anode lead is brought to the outside of the device by neans of a metal film evaporated through an aperture 11 insulating plate 24 after the bonding process. The aperiures in the insulating plate may be formed prior to or after the bonding process. Metal film 25 is continuous on :he surface of insulating plate and thus also serves as an anode contact. A cathode contact 22 is provided by means of a metal film evaporated on the n-portion 21a of slice 21.

The resulting package is an extremely simple and :asily manufactured device with the following advan- Lages: the junction is hermetically sealed in an insulator; )nly two piece parts are required, there is minimum 701111116, area and weight; the silicon may be attached di- 'ectly to a heat sink for improved heat transfer.

In FIGURE 3 the relationship between a silicon traniistor chip, the metallized substrate and the external leads s clearly shown. Silicon chip has metallized connecions 34, and 36 which are to be registered on coresponding metallized connections 39, and 41 of iniulating substrate 38 respectively, Metallized connections 9, 40 and 41 extend on substrate 38 to form external eads 39', 40 and 41 respectively.

In FIGURE 4 the silicon transistor chip 30 is shown )rior to bonding to insulating substrate 38. Transistor :hip 30 is prepared with metallized contacts 34, 35 and 56 contacting the collector 31, base 32 and emitter 33 'egions respectively. The remaining areas are normally arotected by an insulating layer 37 of silicon dioxide grown during the fabrication of the device. Insulating iubstrate 38 has metallized contacts 39, 40 and 41 :vaporated thereon. Pyrex glass metallized with alumi- 1um has been found to be an excellent combination. Fransistor chip 30 is registered on insulating substrate 58 so that metallized areas 34, 35 and 36 of the chip :ontact the corresponding metallized areas 39, 40 and 11 respectively of the substrate. The transistor chip 30 and insulating substrate 38 are then sealed by anodic sending in the manner such as illustrated in the more iimple combinations of FIGURES 1 and 2. Although :he metallized pairs of connections 34, 39 and 35, 40 1nd 36, 41 are in direct contact respectively it has been Found in actual operation that it does not result in short :ircuiting of the bonding circuit therethrough, at least 0 the extent of preventing the formation of the bonding ilm, due probably to the higher resistivity of the glass idjacent the bonding region. As current flows through treas in electric contact the glass adjacent such areas he- :omes impoverished in positive ions by reason of ionic nigration, and a region within the glass adjacent such treas having increased resistivity is formed, and hence he current is diverted to laterally adjacent areas of low- :r resistivity and bonding is progressively effected.

FIGURE 5 is a sectional view of the completed tranlIStOI unit embodying the components of FIGURES 3 and 4. It includes a showing of the oxide layer areas l7 referred to above as grown during fabrication. It will )e understood that according to this invention the bondng can also be carried out on a surface free from oxide. Areas 42, 42, 42" and 42' indicate the anodically formed bond which here again are shown as distinct ayers and in exaggerated dimension for clarity of delCl'lPtlOIl. Metallized portions 39, 40 and 41 on substrate 58 extend past transistor 30 thereby providing external :ontacts. In the practice of the present invention, it is lot necessary to metallize the semiconductor slice. It is iufficient to leave discrete apertures in the oxide film,

if one is present, exposing the appropriate areas of silicon. The aluminum from the substrate makes contact with the silicon areas, thus one step, the metallizing of the semiconductor chip, can be eliminated.

FIGURE 6 represents either of two techniques for interconnectin different silicon elements on a substrate. On the one hand, silicon elements 20 and 30 may be individually mounted as shown. On the other hand, a semiconductor slice 50 containing a plurality of devices may be bonded to an insulating substrate 51 on which a metallized pattern has been deposited to interconnect the ditferent devices according to a predetermined circuit. After bonding, the regions of semiconductor in be tween different devices are removed by etching or any other suitable process to isolate the various semiconductor devices from one another. This eliminates the necessity of individually mounting and registering each device. This scheme may further be utilized to interconnect and encapsulate a plurality of silicon monolithic circuits.

For illustrative purposes a sectional view of a portion of a completed silicon integrated circuit 50 comprising planar diode 20 as described in FIGURE 2 and a transistor 30 as described in FIGURE 3 which have been interconnected and encapsulated are shown in FIGURE 6. Insulating substrate 51 has apertures 60 therein so that metallized portions of substrate 51 can contact appropriate sections of silicon on the various devices. Metal contact 52 connects cathode 21a of diode 20 to the emitter 33 of transistor 30. Metal contact 35 provides an external contact for base 32 of transistor 30 and contact 57 provides an external contact for collector 31 of transistor 30. Similarly, contact 58 provides an external contact for anode 21b of diode 20. Anodically grown film 59 bonds the silicon to the substrate. The metallizing and isolating of the various devices on the slice are carried out after the bonding process.

As described above FIGURE 6 represents either of two techniques for connecting different semiconductors on a substrate. FIGURE 7 illustrates the initial step in one such technique. Insulator substrate 51 has the preformed openings 60 of the final product of FIGURE 6. It is in close planar contact with the individual semiconductors 20 and 30. The substrate 51 preferably has applied thereto a glass plate 70 'for electric current distribution of the several portions of substrate 51, and applied to the plate 70 is the resistive heater strip 71 with its source of electric power 72. The individual semiconductors 20 and 30 each has its independent electric current bonding source indicated at 74 and 75 respectively. If desired they may have a common negative line 76. Line 76 is shown in the set-up of FIGURE 7 as connected to the resistive heater strip 71 which is electrically connected to substrate 51 thnough the current distribution plate 70. As described above in connection with FIGURE 6, application of the bonding currents to the respective semiconductors produces the anodically grown bonding film 59. In the drawings the film 59 may be regarded as comprising the anodioally formed bonding film together with any initial oxide film on the silicon. Following the bonding operation the heater strip 71 and glass plate 70 are of course removed and the metallized pattern 52 is ap plied having the contacts 58, 35 and 57 illustrated in FIGURE 6.

FIGURE 8 illustrates the initial step in another technique for arriving at the device of FIGURE 6. In this case, the substrate indicated at 51, is a solid continuous plate without initially the openings 60, and accordingly the glass distribution plate 70 is omitted. Otherwise the system is similar to that of FIGURE 7 and similar parts bear similar reference characters. Following the formation of the bonding fim 59 the openings 60 are formed as by etching or other suitable means and the metallized pattern 52 is applied which includes the contacts or leads 58, 35 and 57 of FIGURE 6.

As a modification of the techniques of FIGURES 7 and 8 the semiconductor such as the silicon elements 20 and 30 may initially constitute a single integral slice. The initial set-up could then be either like that of FIGURE 7 of FIGURE 8 as desired except that only one bonding circuit (74 or 75) would be required. After the bonding the area of the silicon slice connecting elements 20 and 30 is removed by etching or other means whereby they are electrically isolated from each other and further steps taken as with the techniques described in connection with FIGURES 7 or 8 as the case may be.

The examples heretofore described concern bonding to an insulator a type of component commonly referred to as a semiconductor and having normally a resistivity to electric current in a range considerably higher than metals for example. In addition, however, to applications with semiconductor devices, the anodic bonding process has been found to work in bonding both aluminum and platinum to glass along with a number of other metals, particularly the valve metals. The process has been carried out utilizing a number of insulating materials including glass, quartz and alumina. The process may be carried out in air or in various oxidizing atmospheres, or in a vacuum.

The following examples illustrate the bonding of electrically conducting metals to an insuator, employing in each case a system generally similar in arrangement and principle to that of FIGURE 1, the values given being approximate.

Sheet aluminum was bonded to borosilicate glass using a bonding current density of 1 microampere/mm. for 10 minutes at a temperature of 400 C.

Platinum foil was bonded to soft glass employing a bonding current of 5 microamperes/mm. for 7 minutes at a temperature of 400 C.

Sheet beryllium -was bonded to glass employing a bonding current of 2S microamperes/mm. for 5 minutes at 400 C., and sheet titanium was bonded to glass under similar values of current, time and temperature.

In the ceramic type of glass insulators, palladium was bonded to porcelain employing a bonding current of 100 microamperes/mm. for 5 minutes at 400 C.

It will thus be seen that the invention is adapted to bonding of various insulator materials to various metals of the semiconductor and conductor types. The applicable insulator materials are particularly of the glass type, including ceramic and quartz insulators. As to the metals, the invention is, as has been shown, applicable to a wide range of semiconducting and conducting metals.

The present invention 'has a number of advantages. Among the major ones are:

(1) To encapsulate and provide leads from the planar terials can be accomplished at lower temperatures than 'with competing processes such as glass-to-metal sealing;

(2) Since there is no molten phase, distortion is reduced and dimensional tolerances are improved;

(3) Since the bonding can be made to take place at relatively low temperatures, materials of different thermal expansion coefficient can be attached with less danger of cracking since they do not have to be cooled from such a high temperature, thus thin aluminum below about four mils in thickness has been bonded to glass although its thermal expansion is almost four times as great. Many other metals not norm-ally thought to be scalable to glass may be usable in such applications by virtue of this factor.

The hereinabove invention has a number of applications. In the silicon semiconductor device field, it has been utilized:

(1) To encapsulate and provide leads from the planar surface of a single device; and

(2) To mount, encapsulate the planar surfaces, interconnect and provide leads from a plurality of separate devices on a single substrate.

The invention may be utilized to mount, encapsulate the planar surfaces, interconnect and provide leads from a plurality of silicon monolithic integrated circuits on a single substrate.

Other applications will be apparent to those skilled in the art.

Two alternative methods of providing the interconnections and leads are dscribed. For example, one method is by forming discrete apertures in the substrate, registering the substrate so that the apertures expose appropriate contact areas on the planar surface of the device, devices or circuits and evaporating the metal contacts and leads thereon after the bonding process. A sec-0nd method is by providing metallized contacts on the contact areas of the planar surfaces or exposing discrete areas of silicon, providing corresponding metallized contacts on the substrate, registering the device or devices and the substrate prior to bonding so that the corresponding contacts or contactsilicon areas are registered and bonding so as to effect encapsulation and electrical contact. In the latter instance, the substrate is substantially larger than the silicon chip and the contacts on the substrate terminate in external leads on the area of the substrate extending beyond the chip.

If necessary, the non-planar surface of the device is metallized to provide an additional contact. When a plurality of separate devices or circuits are to be interconnected and encapsulated, they may either be formed on a single slice and isolated by etching, machining or some other appropriate method after bonding or they may be individually registered on the substrate.

It can be seen that the present invention has a wide scope of applications and as hereinabove described and in its representative embodiment is merely illustrative and not exhaustive in scope. Since many widely differing embodiments of the invention may be made without departing from the scope thereof, it is intended that all matters contained in the above description and shown in the accompanying drawing shall be interposed as illustrative and not in a limiting sense.

Having thus described my invention, I claim:

1. A method of bonding an inorganic insulator element of normally high electrical resistivity to a metallic element comprising juxtaposing said elements in surface contact, the adjoining surfaces being substantially smooth and complemental but having points of contact and appreciable gaps, heating said insulator element to a temperature below its fusion point sufficient to render it electrically conductive, applying an electric potential across the juxta posed elements to pass an electric current through said points of contact and create an electrostatic field between the adjoining surfaces causing the juxtaposed elements to be attracted into intimate contact progressively to close said gaps and form a bond between said adjoining surfaces.

2. A method of bonding an insulator element of normally high electrical resistivity inorganic material to a metallic element comprising juxtaposing said elements in surface contact relationship, the adjoining surfaces being substantially smooth and complemental, heating said insulator element to a temperature below its fusion point sufiicient to render it electrically conductive, and applying an electrical potential across the juxtaposed elements whereby said juxtaposed elements are drawn into intimate contact with each other without exertion of substantial mechanical pressure on said juxtaposed elements and a bond is formed between said elements.

3. A method of bonding an insulator element of normally high electrical resistivity inorganic material to a metallic element comprising juxtaposing said elements in surface contact relationship, the adjoining surfaces being substantially smooth and complemental, heating said insulator element to a temperature below its fusion point sufiicient to render it conductive of electric current, and applying an electric potential across the juxtaposed elements sufficient to produce a finite electric current of low amperage density through the juxtaposed elements thereby to produce an electrostatic field across the adjoining surfaces and effecting a bond between the elements in a period of not more than about 20 minutes while the insulator element is at the said electrically conducting temperature.

4. A method of bonding an insulator element of normally high electrical resistivity inorganic material to a metallic element comprising juxtaposing said elements in surface contact relationship, the adjoining surfaces being substantially smooth and complemental, heating said insulator element to a temperature below its fusion point sufficient to render it electrically conductive, and applying an electric potential across the juxtaposed elements through an electrical terminal in electrical contact with said juxtaposed elements, said potential being sufficient to produce a finite electric current of low amperage density through the juxtaposed elements thereby to produce an electrostatic field across the adjoining surfaces and effect a bond between the elements.

5. A method in accordance with claim 1, wherein said temperature is from about 150 C. to about 1200 C.

6. A method in accordance with claim 5, wherein said insulator element is selected from the group consisting of glass, quartz and alumina.

7. A method according to claim 6, wherein said metallic element is selected from the group consisting of aluminum, beryllium, gallium arsenide, germanium, palladium, platinum and silicon.

8. A method according to claim 7, wherein said insulator element is glass.

9. A method according to claim 8, wherein said metallic element is silicon.

10. A method according to claim 8, wherein said metallic element is aluminum.

11. A method according to claim 9, wherein said glass is a borosilicate glass.

12. A method according to claim 7, wherein said potential is DC. and applied to pass a current from said metallic element to said insulator element.

13. A method in accordance with claim 2, wherein said insulator element is a glass, said metallic element is selected from the group consisting of aluminum, beryllium, gallium arsenide, germanium, palladium, platinum and silicon, and said temperature is from about 150 C. to about 1200 C.

14. A method in accordance with claim 3, wherein said insulator element is a glass, said metallic element is selected from the group consisting of aluminum, beryllium, gallium arsenide, germanium, palladium, platinum, and silicon, and said temperature is from about 150 C. to about 1200" C.

15. A method in accordance with claim 4, wherein said insulator element is a glass, said metallic element is selected from the group consisting of aluminum, beryllium, gallium arsenide, germanium, palladium, platinum and silicon, and said temperature is from about 150 C. to about 1200" C.

16. A method of encapsulating a p-n junction of a silicon semiconductor device having a planar surface and providing leads therefrom comprising the steps of:

(a) placing an insulating substrate in contact with the planar surface of said device, said substrate having discrete apertures therein for providing electrical leads from said device, said apertures being aligned with contact areas of said device;

(b) heating said substrate to a temperature below its lfusion point sufficient to render it electrically conductive;

(c) applying an electric potential across said substrate and said device to pass an electric current through the contacting elements thereby to produce an electrostatic field across the contacting elements and effecting a bond between said device and said substrate; and

(d) metallizing discrete areas of said substrate, said metallizing extending to said contact areas of said device exposed by said apertures, thereby providing leads therefrom.

17. A method of encapsulating a p-n junction of a silicon semiconductor device having a planar surface to an insulating substrate and providing a lead from said device comprising the steps of:

(a) placing said substrate contiguous said planar surface of said device;

(b) heating said substrate to a temperature below its fusion point sufficient to render it electrically conductive;

(c) applying an electric potential across said device and said substrate to pass an electric current therethrough thereby to produce an electrostatic field across said device and said substrate and effecting a bond therebetween;

(d) forming an aperture in said substrate for a lead to a contact area of said planar sunface of said device; and

(e) metallizing a discrete area of said substrate, said metallizing extending to said contact areas of said planar surface of said device exposed by said aperture in said substrate thereby providing a lead therefrom.

18. A method for mounting and encapsulating the planar surfaces of a plurality of separate silicon semiconductor devices on a single insulating substrate and providing electrical interconnection therebetween and external leads therefrom comprising the steps of:

(a) placing the insulating substrate contiguous said planar surfaces of said device-s;

(b) heating said substrate to a temperature below its (fusion point sufficient to render it electrically conductive;

(c) applying an electric potential across said substrate and said device to pass an electric current therethrough and effecting a bond between said substrate and each of said devices; and

(d) providing electrical leads from said devices on said substrate including electrical interconnection.

19. A method for mounting a plurality of silicon monolithic integrated circuits on a single insulating substrate and providing electrical interconnection therebetween and external leads therefrom comprising the steps of:

(a) placing an insulating substrate having a discrete metallized pattern thereon contiguous a planar surface of said monolithic circuits so that metallized contacts of said pattern are in electrical connection with said monolithic circuits, said pattern also interconnecting said monolithic circuit and providing leads therefrom;

(b) heating said substrate to a temperature below its fusion point suflicient to render it electrically conductive; and

(c) applying an electric potential across said monolithic circuits and said substrate to pass a positive electric current from said monolithic circuits to said substrate thereby effecting a bond therebetween and holding said metallized pattern of said substrate in electrical contact with said monolithic circuits.

20. As an article of manufacture an inorganic insulator element of normally high electrical resistivity bonded to a metallic element, said article formed according to the process of claim 1.

21. An article of manufacture according to claim 20, wherein said insulator element is selected from the group consisting of glass, quartz and alumina and said metallic element is selected from the group consisting of aluminum, beryllium, gallium arsenide, germanium, palladium, platinum and silicon.

22. An article of manufacture according to claim 21, wherein said insulator element is a glass and said metallic element is silicon.

23. As an article of manufacture an encapsulated p-n References Cited UNITED STATES PATENTS 6/1966 Kramer et a1 156272 9/1951 De Ment 20416 1 4 OTHER REFERENCES Handbook of Chemistry and Physics, 44th edition, 1961, p. 2627.

JOHN H. MACK, Primary Examiner.

T. TUFARIELLO, Assistant Examiner. 

